You beat me to the punch on this POS air box and cover. What a total PITA. I checked my air filter 3 months ago and it was fine. I did have a little trouble with the allen head button bolts. The depth of the allen head is very shallow, and I had a hard time keeping the wrench in the hole and not at an angle. Fast forward to yesterday. I changed engine, trans,sub trans and both filters along with new spark plugs and the air filter.
Now I've been wrenching forever , but I got to say this POS cover is just that. Of course the hardest to reach bolt head got rounded out, and I spent a long time trying to remove it. No way. Can't use an easy out, can't use pliers, can't use anything. In the end I busted of the plastic around the Damm bolt. Only to find out my air filter was almost like new. So I put it all back together, and RTV'ed the crap out of it. I also found,my throttle body clamps loose. What a day. I guess some day ill buy a new air box lid if the sell them separate.
The Japanese are famous for these shallow depth bolt heads. I've had to deal with them on my Suzukis and Kawi's also. The trick is to make sure your allen head wrench is not rounded off at all. I usually dress them up on a grinder wheel, but I didn't do that this time and I played dearly for it. I guess when you service all of your equipment every now and again you mess up
Oh well life goes on, and the pk3 is running good. Here's a picture of what I'm talkin about. Cheers!
